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Intake manifold/seal, Z19

Intake manifold/seal, Z19

To remove

Important

Always use wing covers when working in the engine bay.



1. Remove High-pressure pump, Z19 .

2. Remove EGR solenoid valve (606), Z19.

Warning

Take care if the car is warm. The coolant is hot and there is also a risk of burning yourself on the exhaust manifold.


3. Loosen the coolant expansion tank cap to release any pressure.

4. Raise the car.

5. Remove the front spoiler shield.

6. Place a receptacle under the radiator and drain the coolant. Close the cock and fit the spoiler shield.

7. Lower the car to the floor.

8. Detach the turbocharger delivery hose from the pipe and throttle body.


9. Place a receptacle under the engine to catch the coolant. Detach the coolant hose from the coolant pipe.


10. Detach the coolant hose from the thermostat housing.

11. Remove the nut holding the coolant pipe to the thermostat housing.

12. Remove the nuts holding the coolant pipes to the starter motor bracket. Move the pipes aside slightly to make room for the vacuum reservoir.


13. Detach the vacuum hoses from the vacuum reservoir. Remove the vacuum hose bolts from the camshaft housing and oil trap bracket.


14. Remove the vacuum reservoir.


15. Detach the upper hoses of the oil trap. The right hose has a quick coupling to the oil trap.

16. Remove the nuts and bolts holding the oil trap bracket in place and move it aside.

17. Undo the coolant line from the intake manifold.


18. Detach the wiring harness from the crankcase ventilation pipe. Remove the bolts holding the pipe in place and move it aside.

Cars with preheated crankcase ventilation : Cut the cable ties and remove the brackets.

Important

Take care when releasing the locking mechanism on the connector so as not to damage the connector. Pull the halves straight apart to avoid bending the pins. For further information regarding connectors, refer to Connectors, handling and inspection .


19. Unplug the following connectors:


19.a. Mass air flow sensor connector (686).

19.b. Wiring harness connector. Fit bracket and cable tie.

19.c. A/C compressor connector (170).

19.d. Front temperature sensor (602).

19.e. Camshaft position sensor (555).


19.f. Injectors (206).

19.g. Fuel pressure sensor (653).

19.h. Fuel pressure solenoid valve (652a).

19.i. Electronic throttle actuator (604).

19.j. Intake air sensor (688).

19.k. Glow plug connector (398).

20. Remove the retaining bolts of the cable duct and move the wiring harness aside.

21. Remove the stud holding the high-pressure pump.


22. Unplug the connector of the combustion circulation actuator.

23. Remove the intake manifold.



To fit


1. Fit the intake manifold using a new seal.

Tightening torque 27 Nm (20 lbf ft)


2. Plug in the connector of the combustion circulation actuator.

3. Fit the stud.


4. Attach the coolant pipe to the intake manifold.

Important

Take care when plugging in the connector so as not to damage or press out the pins/sleeves in the connector. For further information regarding connectors, refer to Connectors, handling and inspection .


5. Fit the wiring harness and plug in the following connectors:

5.a. Front temperature sensor (602).


5.b. Camshaft position sensor (555)

5.c. Injectors (206).

5.d. Fuel pressure sensor (653).

5.e. Fuel pressure solenoid valve (652a).

5.f. Throttle body actuator (604)

5.g. Sensor, intake air (688)

5.h. Glow plug connector (398).

5.i. A/C compressor connector.


5.j. Mass air flow sensor connector. (686)

5.k. Wiring harness connector. Fit bracket and cable tie.

6. Cars with preheated crankcase ventilation : Fit the brackets.

7. Fit the bolts holding the crankcase ventilation pipes in place. Fit the wiring harness.

Cars with preheated crankcase ventilation : Secure the wiring harness with cable ties.


8. Reposition the oil trap bracket. Fit the nuts and bolts.


9. Attach the upper hoses of the oil trap.

10. Fit the vacuum reservoir.

Note

The narrow hose connection should be at the top.


11. Attach the vacuum pipes to the camshaft housing and connect the hoses to the vacuum reservoir.


12. Fit the coolant pipes and wiring harness mounting to the starter motor bracket.


13. Secure the wiring harness on the brackets.

14. Attach the coolant hose to the coolant pipe.


15. Fit the nut holding the coolant pipe to the thermostat housing.

16. Attach the coolant hose to the thermostat housing.

Important

To reduce the risk of hoses mounted on the delivery side of the turbocharger coming loose due to low friction at high air pressure, the hoses and connecting pieces must be cleaned thoroughly before fitting. Use a rag dampened with 93 160 907 Motip Dupli cleaning agent to wipe clean inside the ends of the hoses. Clean the connecting pieces as well. If hose clips are rusty or damaged, they must be replaced so the correct clamping force is maintained.


17. Attach the turbocharger delivery hose to the turbocharger delivery pipe and throttle body.


18. Attach the vacuum pipes to the camshaft housing and vacuum tank.

19. Fit High-pressure pump, Z19 .

20. Fit EGR solenoid valve (606), Z19.

21. Pressure test - see Cooling system, pressure testing - and fill coolant - see Filling and bleeding cooling system .

22. Connect an exhaust hose and start the engine. Check for leaks. Connect the diagnostic tool and clear any diagnostic trouble codes.